KR20120057869A - Carbon-ceramic brake disc and method for manufacturing the same - Google Patents

Abstract

PURPOSE: A carbon-ceramic brake disk and a manufacturing method thereof are provided to prevent a carbon-ceramic brake disk from breaking due to sudden disconnecting of pitch-based carbon fiber. CONSTITUTION: A carbon-ceramic brake disk manufacturing method is as follows. Pitch-based carbon fiber and phenol resin are mixed into a mixture(S11). The mixture is inserted a mold and pressed into a molded product(S12). The molded product is carbonized preliminarily(S13). Melted pitch is permeated into the preliminarily molded product and the preliminarily molded product is preliminarily molded product secondarily(S14). The secondarily carbonized molded product is worked mechanically(S15). Silicon liquid is permeated into the worked molded product(S16). The worked molded product is polished(S17).

Description

CARBON-CERAMIC BRAKE DISC AND METHOD FOR MANUFACTURING THE SAME}

The present invention relates to a carbon-ceramic brake disc.

Automobile brakes are divided into drum brakes and disc brakes.

Disc brakes slow or stop the rotation of the disc by the frictional force generated by the friction between the surface of the disc and the pad, thereby slowing down or stopping the vehicle.

Discs with good braking force should be light in weight, have high thermal shock resistance, high oxidation resistance, high wear resistance, high strength, and high coefficient of friction. To this end, in recent years, discs are made of carbon fiber reinforced ceramic composites.

Carbon fiber reinforced ceramic composites are materials in which the matrix is ceramic and reinforced with carbon fibers.

Hereinafter, a brake disc made of a carbon fiber reinforced ceramic composite will be referred to as a carbon-ceramic brake disc.

In general, a carbon-ceramic brake disc includes a step of mixing a phenol resin and carbon fibers to form a mixture, pressurizing and heating the mixture to form a molded body, carbonizing the molded body, and dissolving silicon in the carbonized molded body. It is made through

As the carbon fiber, a fan (PAN, Polyacrylonitrile) -based carbon fiber is used. Fan-based carbon fiber has high strength, high toughness and low brittleness. Thus, it is suitable for use in reinforcing carbon-ceramic brake discs.

However, fan-based carbon fibers react well with silicon. Therefore, in the step of melting and infiltrating silicon into the carbonized molded body, the pan-based carbon fiber is easily eroded by silicon, and the eroded portion becomes silicon carbide (SiC).

1 is a view showing a state in which the fan-based carbon fiber is eroded by silicon, and the carbon of the eroded portion reacts with silicon to become silicon carbide.

As shown in FIG. 1, when the fan-based carbon fiber (Cf-pan) is eroded by silicon, it may be easily broken by an impact during brake operation. In this case, the function of reinforcing the carbon-ceramic brake disc cannot be properly performed.

In order to solve this problem, the applicant has developed a method of making a carbon-ceramic brake disc using pitch-based carbon fibers instead of using fan-based carbon fibers. Pitch-based carbon fibers have lower reactivity with silicon than fan-based carbon fibers. Therefore, using pitch-based carbon fibers solves the silicon erosion problem.

However, pitch-based carbon fibers have small toughness and large brittleness, and may suddenly break when subjected to large stresses. As a result, the strength of the carbon-ceramic brake disc may be weakened and broken.

It is an object of the present invention to provide a carbon-ceramic brake disc and a method of making the same, which are resistant to large stress while using pitch-based carbon fibers having low reactivity with silicon.

A method of making a carbon-ceramic brake disc for achieving the above object comprises: a first step of mixing a pitch-based carbon fiber and a phenol resin to form a mixture; A second step of forming the molded body by pressing the mixture into a mold and pressing the mixture; A third step of carbonizing the molded body firstly; A fourth step of melting and infiltrating a pitch into the first carbonized molded body and secondly carbonizing it; A fifth step of machining the second carbonized molded body; A sixth step of melting and infiltrating silicon into the machined molded body; And a seventh step of polishing the molded body in which the silicon has penetrated.

The object is also achieved by a carbon-ceramic brake disc with randomly distributed pitch-based carbon fibers surrounded by a double carbon matrix.

In addition, the above object, a first step of making a first mixture by mixing the pitch-based carbon fibers and phenolic resin, a first step of making a second mixture by mixing the pitch-based carbon fibers and phenolic resin; A second step of forming a first molded body by putting the first mixture into a mold and pressing the mold with a press, and putting the second mixture into a mold and pressing the press with a press to form a second molded body; A third step of carbonizing the first molded body first and carbonizing the second molded body first; A fourth step of melting and infiltrating a pitch into the first carbonized first molded body and carbonizing it secondly, melting and infiltrating a pitch into the first carbonized second molded body and secondly carbonizing it; A fifth step of machining the second carbonized first molded body and machining the second carbonized second molded body; Attaching the machined first molded body and the machined second molded body to each other; A seventh step of dissolving silicon in the first molded body and the second molded body adhered to each other; And an eighth step of grinding the first molded body and the second molded body in which the silicon has been penetrated.

In addition, the above object, a support layer; A friction layer bonded to upper and lower surfaces of the support layer, respectively; And an adhesive layer formed between the support layer and the friction layer, wherein each of the support layer and the friction layer is achieved by a carbon-ceramic brake disc having randomly distributed pitch-based carbon fibers surrounded by a carbon matrix.

In addition, the above object, a first step of making a first mixture by mixing the pitch-based carbon fibers and phenolic resin, a first step of making a second mixture by mixing the pitch-based carbon fibers and phenolic resin; A second step of forming a first molded body by putting the first mixture into a mold and pressing the mold with a press, and putting the second mixture into a mold and pressing the press with a press to form a second molded body; A third step of carbonizing the first molded body first and carbonizing the second molded body first; A fourth step of melting and infiltrating the pitch into the first carbonized first molded body and secondly carbonizing the first molded body; A fifth step of machining the second carbonized first molded body and machining the second carbonized second molded body; Attaching the machined first molded body and the machined second molded body to each other; A seventh step of dissolving silicon in the first molded body and the second molded body adhered to each other; And an eighth step of grinding the first molded body and the second molded body in which the silicon has been penetrated.

In addition, the above object, a support layer; A friction layer bonded to upper and lower surfaces of the support layer, respectively; And an adhesive layer formed between the support layer and the friction layer, wherein each of the support layer and the friction layer has randomly distributed pitch-based carbon fibers, and only the pitch-based carbon fibers distributed in the support layer are surrounded by a doubled carbon matrix. Achieved by a carbon-ceramic brake disc.

In the present invention, when the pitch-based carbon fiber is subjected to a large stress that cannot be tolerated, the carbon matrix surrounding the pitch-based carbon fiber in double absorbs the stress. Therefore, the pitch-based carbon fibers are suddenly broken, so that the strength of the carbon-ceramic brake disc is weakened and can be prevented from being broken.

1 is a view showing a state in which the fan-based carbon fiber is eroded by silicon, and the carbon of the eroded portion reacts with silicon to become silicon carbide.
Figure 2 is a flow chart illustrating a method of making a carbon-ceramic brake disc according to the first embodiment of the present invention.
FIG.3 (a), (b), (c) is a figure which shows the procedure which makes a molded object from a mixture.
FIG. 4 is a graph showing the temperature and time when melting the pitch into the primary carbonized molded body to infiltrate the secondary carbonized product.
5 is a longitudinal sectional view of a pitch-based carbon fiber in which the carbon matrix is doubled.
FIG. 6 is a graph showing a comparison of the stress-displacement amount between the pitch-based carbon fibers surrounded by the carbon matrix and the pitch-based carbon fibers not surrounded by the carbon matrix.
7 shows a carbon-ceramic brake disc, made by a method of making a carbon-ceramic brake disc according to a first embodiment of the invention.
FIG. 8 is an enlarged view of portion A of FIG. 7.
9 is a flowchart illustrating a method of making a carbon-ceramic brake disc according to a second embodiment of the present invention.
(A), (b), (c) is a figure which shows the procedure which makes a 1st molded object from a 1st mixture.
(A), (b), (c) is a figure which shows the procedure which makes the 2nd molded object from a 2nd mixture.
12 shows a carbon-ceramic brake disc, made by a method of making a carbon-ceramic brake disc according to a second embodiment of the invention.
13 is a flowchart illustrating a method of making a carbon-ceramic brake disc according to the third embodiment of the present invention.

Hereinafter, a method of making a carbon-ceramic brake disc according to the first embodiment of the present invention will be described.

Figure 2 is a flow chart illustrating a method of making a carbon-ceramic brake disc according to the first embodiment of the present invention. FIG.3 (a), (b), (c) is a figure which shows the procedure which makes a molded object from a mixture. The solid arrow shown in FIG. 3 indicates the moving direction of the press, and the dotted arrow indicates the direction in which the molded body is taken out of the mold.

As shown in Figures 2 and 3 (a), (b), (c), a method of making a carbon-ceramic brake disc according to a first embodiment of the present invention,

A first step (S11) of mixing a pitch-based carbon fiber and a phenol resin to form a mixture (X); A second step (S12) of putting the mixture (X) into a mold (M) and pressing the press (P) to form a molded body (Y); A third step (S13) of first carbonizing the molded body (Y); A fourth step (S14) of melting and infiltrating the pitch into the first carbonized molded body (Y) and carbonizing the second; A fifth step S15 of machining the second carbonized molded body Y; A sixth step (S16) of melting and infiltrating silicon into the machined molded body (Y); And a seventh step S17 of polishing the molded body Y penetrated by the silicon.

Hereinafter, the first step S11 will be described.

30 to 70 vol% of the pitch-based carbon fibers and 70 to 30 vol% of the phenol resin are mixed to form a mixture (X).

Hereinafter, the second step S12 will be described.

As shown in FIG. 3 (a), the mixture X is placed in the mold M.

As shown in Fig. 3 (b), the mixture X is pressed by the press P to form the molded body Y. At this time, the pressure to pressurize is 3-5 MPa. Here, the mixture X can also be heated by the heater provided in the press P. The temperature to heat is 120-180 degreeC.

As shown in FIG.3 (c), the molded object Y is taken out from the mold M. As shown to FIG.

The molded body Y is composed of pitch-based carbon fibers randomly distributed in the cured phenolic resin.

Hereinafter, the third step S13 will be described.

The molded object (Y) is placed in a crucible. Put the crucible into the vacuum resistance furnace. It is either a vacuum atmosphere or an inert atmosphere in a vacuum resistance heating furnace.

In vacuum resistance heating, the temperature of the molded object Y is heated up to 1550 degreeC for 13 hours.

In vacuum resistance heating, the temperature of the molded object Y is kept at 1550 degreeC for 1-2 hours.

While the temperature of the molded body Y is raised and maintained at 1550 ° C., the organic compound contained in the molded body Y is thermally decomposed to become carbon. The organic compound is thermally decomposed and porosity is formed in the remaining position.

The fourth step S14 will be described below.

FIG. 4 is a graph showing the temperature and time when melting the pitch into the primary carbonized molded body to infiltrate the secondary carbonized product.

Into the crucible is placed the first carbonized molded body (Y).

The pitch which is a solid state is put in the crucible so that the primary carbonized molded object Y may be buried. The kind of pitch is anisotropic pitch or isotropic pitch.

Put the crucible into the vacuum resistance furnace. It is either a vacuum atmosphere or an inert atmosphere in a vacuum resistance heating furnace.

As shown in FIG. 4, the vacuum resistance heating furnace raises the temperature of the primarily carbonized molded body Y to 330 ° C. for 3 hours. In vacuum resistance heating, the temperature of the molded object Y is kept at 330 degreeC for 10 hours. Since the viscosity of the pitch is lowest at 330 ° C, the pitch penetrates into the molded body Y best while the temperature of the molded body Y is maintained at 330 ° C.

In vacuum resistance heating, the temperature of the molded object Y is heated up to 1000 degreeC for 10 hours. In vacuum resistance heating, the temperature of the molded object Y is kept at 1000 degreeC for 6 hours. In vacuum resistance heating, the temperature of the molded object Y is heated up to 1550 degreeC for 1 hour. In vacuum resistance heating, the temperature of the molded object Y is kept at 1550 degreeC for 2 hours.

While the temperature of the molded body Y is elevated and maintained at 1000 ° C., and is further elevated and maintained at 1550 ° C., while the molded body Y is carbonized secondary, the pitch dissolved in the molded body Y is thermally decomposed to become carbon.

The secondary carbonized molded body Y is cooled to room temperature in a vacuum resistance heating furnace.

5 is a longitudinal sectional view of a pitch-based carbon fiber in which the carbon matrix is doubled.

As shown in FIG. 5, the carbon matrix C1 generated during the first carbonization surrounds the pitch-based carbon fiber Cf-pitch, and the carbon matrix C2 generated during the second carbonization is the carbon fiber Cf-pitch. Surround).

FIG. 6 is a graph showing a comparison of the stress-displacement amount between the pitch-based carbon fibers surrounded by the carbon matrix and the pitch-based carbon fibers not surrounded by the carbon matrix. The solid line represents the stress-displacement curve of the pitch-based carbon fiber surrounded by the carbon matrix in double, and the dotted line represents the stress-displacement curve of the pitch-based carbon fiber surrounded by the carbon matrix.

As shown in FIG. 6, the pitch-based carbon fiber not surrounded by the carbon matrix continues to increase in proportion to the stress, and at the cutting point E, it no longer bears a large stress and is suddenly broken.

On the other hand, the pitch-based carbon fiber in which the carbon matrix is doubled increases in proportion to the stress, but is gradually cut from the cutting point (H) after the plastic point (F) is no longer proportional to the stress and is increased by the displacement amount (G). The reason is that the carbon matrix surrounding the pitch-based carbon fibers in a double absorbs the large stresses that the pitch-based carbon fibers cannot withstand and transfers only the remaining small stresses to the pitch-based carbon fibers.

Hereinafter, a fifth step S15 will be described.

A shaft hole through which the axle passes is formed in the center of the molded body (Y).

Around the axial hole of the molded body (Y), a through hole through which a bolt coupled with a hat part passes, is drilled at equal intervals on the same circle. The hat part is combined with the wheels.

The sixth step S16 will be described below.

Put the silicon in the crucible.

Into the crucible is placed so that the lower part of the molded body (Y) is buried in silicon. Silicon is piled up on the molded body Y.

Put the crucible into the vacuum resistance furnace. It is either a vacuum atmosphere or an inert atmosphere in a vacuum resistance heating furnace.

In vacuum resistance heating, the temperature of the molded object Y is heated up to 1550 degreeC for 13 hours.

In vacuum resistance heating, the temperature of the molded object Y is kept at 1550 degreeC for 1-2 hours.

While the temperature of the molded body Y is raised and maintained at 1550 ° C., the silicon melts and penetrates into the pores of the molded body Y.

Most of the silicon penetrated into the pores reacts with the carbon contained in the molded body (Y) to become silicon carbide (SiC). The remaining silicon that does not react with carbon fills the pores.

The seventh step S17 will be described below.

The molded object Y is polished with a grinder.

7 shows a carbon-ceramic brake disc, made by a method of making a carbon-ceramic brake disc according to a first embodiment of the invention.

As shown in Fig. 7, the carbon-ceramic brake disc 10 made by the method of making the carbon-ceramic brake disc according to the first embodiment of the present invention is composed of a single body.

The carbon-ceramic brake disc 10 has a shaft hole 11 through which an axle passes. Around the shaft hole 11, through-holes 12 through which bolts coupled with hat parts pass through are provided on the same circle at equal intervals.

The thickness of the carbon-ceramic brake disc 10 is 20-50 mm.

The composition of the carbon-ceramic brake disc 10 is 65-25 wt% of SiC, 15-25 wt% of Si, and 20-50 wt% of C.

FIG. 8 is an enlarged view of portion A of FIG. 7.

As shown in FIG. 8, a short (1-3 mm) long pitch (Cf-pitch) and a long (25-30 mm) pitch carbon fiber (Cf-pitch) are randomly distributed. . The pitch-based carbon fiber is composed of a bundle of filament 1K to 48K having a diameter of 7 µm.

The reason that the long pitch carbon fibers and the short pitch carbon fibers are mixed is that when only the long pitch carbon fibers are distributed, the contact area between the pitch carbon fibers and the air increases and the pitch carbon fibers are oxidized. On the other hand, when only a short pitch-based carbon fiber is distributed, the reinforcing function of the pitch-based carbon fiber is reduced.

As shown in FIG. 8, the carbon matrix C1 generated during the first carbonization mainly surrounds the pitch-based carbon fibers Cf-pitch. The carbon matrix C2 produced during the secondary carbonization surrounds the pitch-based carbon fiber (Cf-pitch) secondaryly. Part of the secondary enclosed carbon matrix (C2) reacts with silicon to form silicon carbide (SiC) in the step of infiltrating silicon into the formed body.

9 is a flowchart illustrating a method of making a carbon-ceramic brake disc according to a second embodiment of the present invention. (A), (b), (c) is a figure which shows the procedure which makes a 1st molded object from a 1st mixture. (A), (b), (c) is a figure which shows the procedure which makes the 2nd molded object from a 2nd mixture. The solid arrow shown in FIG. 10 or 11 shows the moving direction of the press, and the dotted arrow shows the direction in which the first molded body or the second molded body is taken out of the mold.

9, 10 (a), (b), (c), 11 (a), (b) and (c), the carbon-ceramic brake disc according to the second embodiment of the present invention. How to make,

A first step (S21) of mixing a pitch-based carbon fiber and a phenol resin to make a first mixture (X1), and mixing a pitch-based carbon fiber and a phenol resin to form a second mixture (X2); The first mixture (X1) is put into the mold (M) and pressed with a press (P) to make a first molded body (Y1), the second mixture (X2) is put into a mold (M) and pressed with a press (P). A second step S22 of making a second molded body Y2; A third step (S23) of first carbonizing the first molded body (Y1) and first carbonizing the second molded body (Y2); A fourth step (S24) of melting and infiltrating the first molded body (Y1) firstly carbonized and carbonizing the secondary, and melting and infiltrating the first molded carbon (Y2) and the second carbonizing; A fifth step (S25) of machining the second carbonized first molded body (Y1) and machining the second carbonized second molded body (Y2); A sixth step (S26) of adhering the machined first molded body (Y1) and the machined second molded body (Y2) to each other; A seventh step (S27) of dissolving silicon in the first molded body (Y1) and the second molded body (Y2) adhered to each other; And an eighth step (S28) of grinding the first molded body (Y1) and the second molded body (Y2) in which the silicon has penetrated.

Hereinafter, the first step S21 will be described.

30 to 70 vol% of pitch-based carbon fibers and 70 to 30 vol% of a phenol resin are mixed to form a first mixture (X1). A support layer to be described later is made of the first mixture X1.

30-70 vol% of pitch-based carbon fibers and 70-30 vol% of a phenol resin are mixed to form a second mixture (X2). A friction layer to be described later is made of the second mixture X2.

Hereinafter, the second step S22 will be described.

As shown in FIG. 10A, the first mixture X1 is placed in the mold M. As shown in FIG.

The core body V is placed on the first mixture X1. The core body V has the shape of a cooling channel. The first mixture X1 is placed on the core body V.

As shown in FIG. 10 (b), the first molded body Y1 is formed by pressing the press P. FIG. At this time, the pressure to pressurize is 3-5 MPa. Here, the first mixture X1 may be heated by a heater provided in the press P. The temperature to heat is 120-180 degreeC.

As shown in FIG. 10 (c), the first molded object Y1 is taken out of the mold M. As shown in FIG.

The first molded product Y1 is composed of pitch-based carbon fibers randomly distributed in the cured phenolic resin.

As shown in FIG. 11A, the second mixture X2 is placed in the mold M. As shown in FIG.

As shown in FIG. 11 (b), the second mixture X2 is pressed by the press P to form the second molded body Y2. At this time, the pressure to pressurize is 3-5 MPa. Here, the second mixture X2 may be heated by a heater provided in the press P. The temperature to heat is 120-180 degreeC.

As shown in FIG. 11 (c), the second molded body Y2 is taken out of the mold M. As shown in FIG.

The second molded product Y2 is composed of pitch-based carbon fibers randomly distributed in the cured phenolic resin.

Hereinafter, the third step S23 will be described.

The first molded product Y1 is first carbonized. The second molded product Y2 is first carbonized. Since the method of first carbonizing the first molded body Y1 and the second molded body Y2 is the same as the method of first carbonizing the molded body in the first embodiment, the description thereof is omitted.

When carbonizing the first molded body Y1, the core body V is pyrolyzed. The amount of residual carbon upon thermal decomposition of the core body (V) is preferably less than 10 wt%. To this end, the core body (V) is made of a thermoplastic resin such as polycarbonate, ABS resin (Acrylonitrile Butadiene Styrene copolymer), styrene resin, polyethylene, acrylic resin and the like. When the core body V is thermally decomposed, the core body V is pyrolyzed and cooling channels are formed in the remaining empty space.

The fourth step S24 will be described below.

The pitch is melted and infiltrated into the first molded body Y1 that is first carbonized, and secondly carbonized. Pitch is melted and infiltrated into the first molded carbon Y2, and carbonized secondly. The method of melting and infiltrating the pitch into the first carbonized first molded body (Y1) and the second molded body (Y2) and carbonizing it in the second embodiment, in the first embodiment is to melt the pitch into the first carbonized molded body to penetrate and carbonize secondary Since it is the same as the method, the description is omitted.

The fifth step S25 will be described below.

The axle passes through the shaft hole in the center of the first molded body (Y1) and the second molded body (Y2).

Through-holes through which bolts coupled with hat parts pass through the axial hole of the first molded body Y1 and the second molded body Y2 are drilled at equal intervals on the same circle. Hat parts are combined with wheels.

The sixth step S26 will be described below.

Liquid phenolic resin is applied to the upper and lower surfaces of the first molded body Y1. Coating thickness is 0.1 ~ 2mm. The second molded object Y2 is adhered to the upper and lower surfaces of the first molded object Y1. The phenolic resin in the liquid state exiting between the first molded object Y1 and the second molded object Y2 is removed.

Alternatively, a solid phenolic resin is sprinkled on the upper and lower surfaces of the first molded body Y1. The second molded body Y2 is placed on the upper and lower surfaces of the first molded body Y1, respectively, and is pressed by a press and heated by a heater installed in the press. As the phenolic resin in the solid state is melted, the second molded body Y2 is adhered to the upper and lower surfaces of the first molded object Y1. The phenol resin of the liquid state (the solid phenol resin melt | dissolved) which escaped between the 1st molded object Y1 and the 2nd molded object Y2 is removed.

When the first molded object Y1 and the second molded object Y2 are bonded together, an adhesive layer to be described later is formed between the first molded object Y1 and the second molded object Y2.

The seventh step S27 will be described below.

The silicon is melted and infiltrated into the first molded body Y1 and the second molded body Y2 adhered to each other. Since the method of dissolving silicon in the first molded product Y1 and the second molded product Y2 bonded to each other is the same as the method of infiltrating silicon into the molded product in the first embodiment, the description thereof is omitted.

The eighth step S28 will now be described.

The first molded object Y1 and the second molded object Y2 are polished by a grinder.

12 shows a carbon-ceramic brake disc, made by a method of making a carbon-ceramic brake disc according to a second embodiment of the invention.

As shown in FIG. 12, the carbon-ceramic brake disc made by the method of manufacturing the carbon-ceramic brake disc according to the second embodiment of the present invention may be formed of the support layer 110, the friction layer 120, and the adhesive layer 130. It is composed.

The carbon-ceramic brake disc 100 has a shaft hole 101 through which the axle passes. Around the shaft hole 101, through-holes 102 through which bolts coupled with hat parts pass, are provided at the same interval on the same circle.

The support layer 110 has a cooling channel 111. The thickness of the support layer 110 is 20-50 mm. The composition of the support layer 110 is SiC 65-25 wt%, Si 15-25 wt%, C 20-50 wt%.

The thickness of the friction layer 120 is 0.1 ~ 2mm. The composition of the friction layer 120 is the same as the composition of the support layer 110, SiC 65-25 wt%, Si 15-25 wt%, C 20-50 wt%.

Since the composition of the support layer 110 and the composition of the friction layer 120 are the same, the coefficient of thermal expansion of the support layer 110 and the coefficient of thermal expansion of the friction layer 120 are the same. Therefore, in the process of making the carbon-ceramic brake disc 100, cracks do not occur in the friction layer 120 due to a difference between the thermal expansion coefficient of the support layer 110 and the thermal expansion coefficient of the friction layer 120.

In the support layer 110, pitch-based carbon fibers are randomly distributed. The pitch-based carbon fiber is composed of a bundle of filament 1K to 48K having a diameter of 7 µm. The pitch-based carbon fiber included in the support layer 110 is 10 to 30 mm in length. The pitch-based carbon fibers included in the support layer 110 are double surrounded by a carbon matrix, and a part of the outer carbon reacts with silicon to become silicon carbide.

In the friction layer 120, pitch-based carbon fibers are randomly distributed. The pitch-based carbon fiber included in the friction layer 120 is composed of a bundle of filaments 1K to 48K having a diameter of 7 µm. The pitch-based carbon fiber included in the friction layer 120 is 1 to 3 mm. The pitch-based carbon fibers included in the friction layer 120 are double surrounded by a carbon matrix, and a part of the outer carbon matrix reacts with silicon to become silicon carbide.

On the other hand, the pitch-based carbon fiber contained in the friction layer 120, the friction layer 120 is exposed to the outside, it is easy to oxidize with air. Therefore, in order to minimize the contact area with air, the pitch-based carbon fibers included in the friction layer 120 is shorter than the length of the pitch-based carbon fibers included in the support layer 110. Even if the length of the pitch-based carbon fiber is short, the strength of the friction layer 120 can be sufficiently maintained since the friction layer 120 is relatively less impacted than the support layer 110 during the brake operation.

The thickness of the adhesive layer 130 is 0.1-1 mm. The composition of the adhesive layer 130 is 50 wt% of SiC, 45 wt% of Si, and 5 wt% of C.

13 is a flowchart illustrating a method of making a carbon-ceramic brake disc according to the third embodiment of the present invention.

As shown in FIGS. 10 (a), (b), (c), 11 (a), (b), (c), and 13, a carbon-ceramic brake disc according to a third embodiment of the present invention Method of making, the first step (S31) to form a second mixture (X2) by mixing the pitch-based carbon fiber and phenol resin to make a first mixture (X1); The first mixture (X1) is put into the mold (M) and pressed with a press (P) to make a first molded body (Y1), the second mixture (X2) is put into a mold (M) and pressed with a press (P). A second step S32 of forming a second molded body Y2; A third step (S33) of first carbonizing the first molded body (Y1) and first carbonizing the second molded body (Y2); A fourth step (S34) of melting and infiltrating a pitch into the first carbonized first molded body (Y1) and secondly carbonizing it; A fifth step (S35) of machining the second carbonized first molded body (Y1) and machining the second carbonized second molded body (Y2); A sixth step (S36) of adhering the machined first molded body (Y1) and the machined second molded body (Y2) to each other; A seventh step (S37) of dissolving silicon in the first molded body (Y1) and the second molded body (Y2) adhered to each other; And an eighth step (S38) of grinding the first molded body (Y1) and the second molded body (Y2) in which the silicon has penetrated.

In the method of manufacturing the carbon-ceramic brake disc according to the third embodiment of the present invention, the pitch is melted and infiltrated only into the first molded product Y1 that is primarily carbonized, and then carbonized secondly and the second molded product Y2 is first carbonized. ) Is not carbonized after the melt is penetrated. Except for this, it is the same as the method of making the carbon-ceramic brake disc according to the second embodiment.

In the carbon-ceramic brake disc made by the method of making the carbon-ceramic brake disc according to the third embodiment of the present invention, only the pitch-based carbon fiber distributed in the support layer is doubled by the carbon matrix. Except for this, it is the same as the carbon-ceramic brake disc made by the method of making the carbon-ceramic brake disc according to the second embodiment.

In the method of making the carbon-ceramic brake disc according to the third embodiment of the present invention, since the support layer is subjected to a greater stress than the friction layer during the brake operation, the carbon-ceramic brake disc is doubled in the carbon matrix up to the pitch-based carbon fiber included in the friction layer. It was created because there is little need to surround it. In addition, when the pitch-based carbon fiber contained in the friction layer is enclosed in double by a carbon matrix, the friction layer has a large amount of carbon, so that the friction layer is easily oxidized.

Claims (9)

A first step of mixing a pitch-based carbon fiber and a phenol resin to form a mixture;
A second step of forming the molded body by pressing the mixture into a mold and pressing the mixture;
A third step of carbonizing the molded body firstly;
A fourth step of melting and infiltrating a pitch into the first carbonized molded body and secondly carbonizing it;
A fifth step of machining the second carbonized molded body;
A sixth step of melting and infiltrating silicon into the machined molded body; And
And a seventh step of grinding the molded body in which the silicon is infiltrated. The method according to claim 1, wherein in the fourth step, the temperature of the first carbonized molded body is raised to 330 ° C for 3 hours, maintained at 330 ° C for 10 hours, heated to 1000 ° C for 10 hours, and 1000 for 6 hours. A method of making a carbon-ceramic brake disc, which is maintained at < RTI ID = 0.0 > C, < / RTI >  Carbon-ceramic brake discs with randomly distributed pitch-based carbon fibers surrounded by a double carbon matrix. A first step of making a first mixture by mixing pitch-based carbon fibers and phenol resins, and making a second mixture by mixing pitch-based carbon fibers and phenol resins;
A second step of forming a first molded body by putting the first mixture into a mold and pressing the mold with a press, and putting the second mixture into a mold and pressing the press with a press to form a second molded body;
A third step of carbonizing the first molded body first and carbonizing the second molded body first;
A fourth step of melting and infiltrating a pitch into the first carbonized first molded body and carbonizing it secondly, melting and infiltrating a pitch into the first carbonized second molded body and secondly carbonizing it;
A fifth step of machining the second carbonized first molded body and machining the second carbonized second molded body;
Attaching the machined first molded body and the machined second molded body to each other;
A seventh step of dissolving silicon in the first molded body and the second molded body adhered to each other; And
And an eighth step of grinding the first molded body and the second molded body in which the silicon has penetrated. The method of claim 4, wherein in the fourth step, the temperature of each of the first carbonized first molded body and the second molded body is raised to 330 ° C for 3 hours, maintained at 330 ° C for 10 hours, and 1000 ° C for 10 hours. To make a carbon-ceramic brake disc which is heated to 1000 ° C. for 6 hours, heated to 1550 ° C. for 1 hour, kept at 1550 ° C. for 2 hours, and cooled to room temperature. Support layer;
A friction layer bonded to upper and lower surfaces of the support layer, respectively; And
Consists of an adhesive layer formed between the support layer and the friction layer,
Each of the support layer and the friction layer, the carbon-ceramic brake disc is a random distribution of pitch-based carbon fibers surrounded by a double carbon matrix. A first step of making a first mixture by mixing pitch-based carbon fibers and phenol resins, and making a second mixture by mixing pitch-based carbon fibers and phenol resins;
A second step of forming a first molded body by putting the first mixture into a mold and pressing the mold with a press, and putting the second mixture into a mold and pressing the press with a press to form a second molded body;
A third step of carbonizing the first molded body first and carbonizing the second molded body first;
A fourth step of melting and infiltrating the pitch into the first carbonized first molded body and secondly carbonizing the first molded body;
A fifth step of machining the second carbonized first molded body and machining the second carbonized second molded body;
Attaching the machined first molded body and the machined second molded body to each other;
A seventh step of dissolving silicon in the first molded body and the second molded body adhered to each other; And
And an eighth step of grinding the first molded body and the second molded body in which the silicon has penetrated. The method of claim 7, wherein, in the fourth step, the temperature of the first carbonized first molded body is raised to 330 ° C. for 3 hours, maintained at 330 ° C. for 10 hours, heated to 1000 ° C. for 10 hours, and 6 hours. A carbon-ceramic brake disc which is maintained at 1000 ° C. for 1 hour, heated to 1550 ° C. for 1 hour, maintained at 1550 ° C. for 2 hours, and cooled to room temperature. Support layer;
A friction layer bonded to upper and lower surfaces of the support layer, respectively; And
Consists of an adhesive layer formed between the support layer and the friction layer,
In each of the support layer and the friction layer, pitch-based carbon fibers are randomly distributed,
A carbon-ceramic brake disc only doubled by a carbon matrix, pitch-based carbon fibers distributed in the support layer.

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